Note: Descriptions are shown in the official language in which they were submitted.
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OBJECT WASHING APPARATUS
The present apparatus relates to the washing of objects in a
production environment as part of the manufacturing process.
It is often necessary to wash manufactured obj ects to remove
contaminants, such as lubricants, that may be introduced during the
manufacturing
process. One type of manufactured obj ect that commonly requires washing is a
container. A particular type of container, connnonly referred to as a "can",
is
typically constructed from a metallic material, such as steel or aluminum.
Cans have long been used as containers for storing and dispensing
beverages. The type of beverage can most commonly used today is known in the
can-making industry as a "two-piece" can. Aptly enough, this type of can is
constructed of two pieces - a body portion and a closure member.
A typical two-piece beverage can includes a body portion and an end
member attached to the body portion. The can body portion comprises a
generally
cylindrical portion which has an open end and a closed end. The open end is
generally provided with a necked-in portion, commonly referred to in the
industry
as a "neck". The can neclc typically terminates in a flanged end, which is
commonly referred to in the industry as a "flange". The flange facilitates
attachment of the can end to the can body. The neclc allows an end to be used
which is smaller in diameter than the cylindrical portion of the can body.
The closed end of the can body portion generally includes an annular
rim and an inwardly domed portion. The domed portion is configured to resist
the
pressure generated by a beverage contained within the can, particularly a
carbonated
beverage. In this manner, the can may be placed andlor conveyed on a flat
surface
in a stable fashion resting on the rim.
The can body portion is most commonly constructed of steel or
aluminum and is formed by a drawing and ironing process in which a can preform
or "cup" is forced through a series of dies by a punch. In a typical drawing
and
ironing process, the cup first moves through a redraw die which causes the cup
to
conform to the shape of the punch. The punch then forces the redrawn cup
through
a series of ironing dies which stretch and thin the metal into an elongated
cylindrical configuration. The sidewalls of drawn and ironed cans may, for
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example, only be about 0.004 inches thick at the thinnest part of the can
sidewall.
After clearing the ironing dies, the punch causes the closed end of the can to
impact
a doming die which creates the rim and domed profile described above.
The process outlined above may be carried out in a machine of the
type commonly referred to in the industry as a "bodymaker" or a "wall ironer".
Examples of a bodymalcer machine are disclosed in U.S. Patents 3,696,657 to
Maytag and 5,357,779 to Hahn et al., which are hereby specifically
incorporated by
reference for all that is disclosed therein.
After being drawn and ironed into a cylindrical configuration, the can
body is trimmed to a desired height in a can trimming maclune. Examples of
such
a can trimming machine are disclosed in U.S. Patents 5,404,776 and 5,054,341
to
Johansson et al. which are hereby specifically incorporated by reference for
all that
is disclosed therein.
After trimming, the can body is generally provided with an exterior
decoration and an internal coating to prevent contact between the can contents
and
the metal forming the can. After decorating and coating, the can is then
transferred
to a machine or machines which form the neck and the flange as previously
described. An example of a machine which neclcs and flanges cans is disclosed
in
U.S. Patent Number 3,687,098 to Maytag which is hereby specifically
incorporated
by reference for all that is disclosed therein.
At this point, the can body is completely formed and is ready to be
filled with a beverage and sealed with an end. An example of a can end is
disclosed in U.S. Patent Number 4,901,880 to Tatham et al. which is hereby
specifically incorporated by reference for all that is disclosed therein.
During the can manufacturing process, as outlined above, the can
body may be exposed to various lubricants and coolants. In the bodymaker
machine, for example, a coolant may be used in order to cool the can and the
dies
as the can body is formed. Tlus coolant may also include one or more
lubricants in
order to reduce the friction between the can body and the dies as the can is
formed.
Accordingly, at the time that a can exits the trimming machine, it will
generally be
coated with bodymalcer coolant. In addition, lubricant previously applied to
the cup
or preform may still be present on the formed can at this point. Since the
existence
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of such lubricants and coolants interferes with the ability to effectively
decorate and internally coat the can body, as described above, it is
conventional to
pass formed can bodies through a can washer after they are trimmed and before
they enter the can decorator.
Conventional can washers are long conveyer-belt lines. A bottom
conveyer belt supports the cans as they enter, travel through, and egress from
the
conventional can washer. A top conveyer belt traps the cans during spraying
operations as described herein. The conventional can washer receives a
plurality of
cans at an upstream end. The cans are received by the conventional can washer
in a
random pattern whereby the cans are grouped together. Since the cans are
grouped
together, they touch each other resulting in long small 'tubes' of space
between each
can. The cans travel down the length of the conventional can washer going
through
a variety of cleaning operations. A prewashing station is provided for
spraying a
solution of prewash solution. As the cans travel through the prewashing
station, the
top belt traps the cans in order to overcome the force of the prewashing
solution.
The prewashing solution is sprayed through the top and bottom conveyor belts
onto
the cans. A significant amount of the prewashing solution is deflected by the
top
and bottom conveyer belts as a result of their required surface area to
support the
cans.
At a downstream position from the prewashing station, a washing
station is provided for spraying a solution of conventional wash solution. As
the
cans travel through the washing station, the top belt traps the cans in order
to
overcome the force of the washing solution. The washing solution is sprayed
through the top and bottom conveyor belts. As previously mentioned, a
significant
amount of the washing solution is deflected by the top and bottom conveyer
belts as
a result of their required surface area to support the cans.
A rinse station is located downstream from the washing station. The
rinse station sprays a solution of potable water onto the cans in order to
remove the
washing solution.
A final rinse station is located downstream from the washing station.
The final rinse station sprays a solution of deionized water onto the cans in
order to
ensure that contaminate-free cans egress from the conventional can washer.
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In-between the individual washing and rinsing stations are baffles for
blowing off any remaining solutions. The baffles are air screens produced by
blowing high-pressure air through nozzles. The baffles blow any remaining
solution
off of the cans in order to minimize cross-contamination of the various
solutions.
Such air baffles are substantially disclosed in U.S. Patent Number 4,183,115
to
Zakarian hereby specifically incorporated by reference for all that is
disclosed
therein.
A conventional can washer is capable of washing about 3000 cans per
minute. At this rate, there are a large number of cans traveling on the bottom
conveyer belt through the conventional can washer. Due to the large number of
cans, the conventional can washer is a large system. The conventional can
washer
accepts cans from a plurality of bodymaker machines. After washing the cans,
the
cans are etched (a process for activating a metal surface to accept printing)
and then
delivered to a can decoration machine as described above.
The individual components of the can manufacturing process are
susceptible to malfunctioning. In the event that a malfunction occurs, the
entire can
line often must be shut down. Due to the number of cans in the flow process,
if a
malfunction occurs at any location in the production line, the conventional
can
washer is slowed down. The slowing down of the conventional can washer may
result in over-treatment of the cans. Over-treatment of the cans results in
defective
cans that need to be removed and discarded. Defects. caused by over-treating
may
include color variations, problems in the necking region and friction in
conveyor
systems. Removing and discarding cans represents an economic loss, requiring
extra time and manual labor.
An additional consideration associated with conventional can washers
is the size of the can washer. Because all of the cans are received from a
plurality
of bodymalcer machines, the actual size of the conventional can washer is
rather
large. The individual tanks holding the various cleaning solutions are
proportionally
large. In the event that a solution becomes contaminated, off ratio, or
otherwise
unacceptable, changing or rejuvenating the solution becomes expensive and
difficult
due to the size of the tanks.
In addition to being used as containers for beverages, as generally
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discussed above, cans also find use as containers for storing other products,
such as
foods. Although two-piece cans are sometimes used for food products, a type of
can commonly referred to as a "three-piece can" is more commonly used for this
purpose.
During the manufacture of a typical three-piece can, a body portion is
formed from a flat, typically rectangular, portion of steel. The portion is
rolled into
a cylindrical shape and then welded to form an annular can body that is open
at
both ends. The rectangular portion may be decorated prior to the rolling and
welding operations or a label may be applied after the can is filled. After
rolling
and welding, an end is then seamed to one end of the can body. Thereafter, the
interior of the can may be supplied with an internal coating, similar to the
internal
coating applied to a two-piece can as discussed above.
Prior to applying the internal coating, as described above, three-piece
cans may be washed, in a manner similar to that described above, in order to
remove lubricants or other contaminants that may have been introduced during
the
can manufacturing process. Accordingly, the problems discussed above, with
respect to two-piece can washing are also applicable to a three-piece can
manufacturing process.
In one embodiment a washer for washing obj ects may have a housing
and a rotatable member rotatably mounted to the housing at a rotation axis.
The
rotatable member may have an outer peripheral surface extending in a direction
parallel to the rotation axis. The washer may have at least one stationary
member
stationarily mounted to the housing. Furthermore, at least one of the objects
may be
in contact with both the rotatable member outer peripheral surface and the
stationary
member.
In another embodiment a method of washing an object may include
providing a housing, providing at least one nozzle within the housing and
providing
a rotatable member rotatably mounted to the housing at a rotation axis. The
rotatable member may have an outer peripheral surface extending in a direction
parallel to the rotation axis. The method may further include providing at
least one
stationary member stationarily mounted to the housing, rotating the rotatable
member and causing the object to move relative to the housing by contacting
the
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object with the rotatable member outer peripheral surface. The method may
further
include guiding the object within the housing by contacting the object with
the at
least one stationary member and spraying fluid from the at least one nozzle
onto the
obj ect while the rotating and the guiding are occurring.
In another embodiment a washer for washing objects may have a
housing, a rotatable member rotatably mounted to the housing at a rotation and
at
least one stationary member stationarily mounted to the housing. At least one
of the
objects may be located between the rotatable member and the at least one
stationary
member. At least one of the objects may be in contact with both the rotatable
member and the stationary member.
Fig. 1 shows a top perspective of a can washer with a cover attached
thereto.
Fig. 2 shows a top perspective of the can washer of Fig. 1 with the
cover removed, thereby showing internal components.
Fig. 3 shows a side perspective of a spray manifold that may be one
of the internal components shown in Fig. 2.
Fig. 4 shows a side perspective of a top air manifold that may be one
of the internal components shown in Fig. 2.
Fig. 5 shows a side perspective of a circular air manifold that may be
one of the internal components shown in Fig. 2.
Fig. 6 shows a top perspective of a retention turntable that may be
one of the internal components shown in Fig. 2.
Fig. 7 shows a cut-away side view of the retention turntable of Fig. 6
and a can, the cut-away portion is shown in Fig. 2 as line 7-7.
Fig. 8 shows a cut-away side view of the can washer, the cut-away
portion is shown in Fig. 2 as line 8-8.
Prior to providing detailed descriptions of the individual components
of a high-speed can washer 100, a preliminary overview will be provided.
Referring to Fig. 1, the high-speed can washer 100 may be provided
with a machine base 200, a tanl~ assembly 300, a plurality of wash manifolds
such
as wash manifold 450 (Fig. 3), a plurality of top air manifolds such as top
air
manifold 550 (Fig. 4), a plurality of circular air manifolds such as circular
air
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manifold 600 (Fig. 5), a retention turntable 700, a cover 900, an entrance
portion
130 and an exit portion 132.
The can washer 100 may be provided for receiving a plurality of cans
such as can 150 at the entrance portion 130, engaging the retention turntable
700
and progressing into the cover 900. While traveling in the cover 900 in a
rotary
direction 160, various cleaning operations may be performed to the can 150 at
a
plurality of stations in order to remove various contaminates. After traveling
in the
rotary direction 160 under the cover 900, the can 150 may egress from the can
washer 100 at the exit portion 132. The can 150 that egresses from the exit
portion
132 being clean and substantially contaminate-free.
Having provided a brief introduction to an exemplary embodiment of
the present high-speed can washer, a detailed description of the subsystems
and
components thereof will now be provided.
With reference to Fig. 8, the can washer 100 may be provided with a
machine frame 200 with various components attached thereto. The machine frame
200 may be manufactured in the exemplary embodiment of welded structural
tubing
to provide a substantially rigid structure. The machine frame 200 may be
provided
with leveling pads, such as a first leveling pad 202 and a second leveling pad
204
for leveling the can washer 100. The machine frame 200 may be further provided
with a plurality of bearings such as bearing 206. The machine frame 200 may be
further provided with a motor mount (not shown) for receiving a motor (not
shown).
Referring to Fig. 2, a tame assembly 300 may be provided as a
component of the can washer 100. In an exemplary embodiment, the tank assembly
300 is configured in a substantially circular geometry having a
circumferential wall
portion 302. The tank assembly 300 may be further provided with a tank
entrance
wall portion 304, a tanlc exit wall portion 306 and a center wall portion 308.
The
individual wall portions 302, 304, 306 and 308 are configured perpendicular to
a
bottom portion 310. The wall portions 302, 304, 306 and 308 and the bottom
portion 310 may be assembled to define an outside tank perimeter 312 of the
tank
assembly 300. In the exemplary embodiment the tank assembly 300 may be welded
steel constructed with water impermeable joints.
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The outside tank perimeter 312 may be provided with internal
partitions to create a plurality of individual tanlcs for receiving various
solutions.
The plurality of internal partitions may include partitions such as a prewash
partition
340, a prewash dryer partition 342, a wash partition 344, a wash dryer
partition 346,
a rinse partition 348, a rinse dryer partition 350 and a final rinse partition
360. The
plurality of individual tanks may include tanks such as a prewash tank 320, a
prewash dryer recovery tank 322, a wash tank 324, a wash dryer recovery tank
326,
a rinse tank 328, a rinse dryer recovery tank 330, a final rinse tank 332 and
a final
dryer tank 334.
The prewash tank 320 is separated from the prewash dryer recovery
tanlc 322 by the prewash partition 340. The prewash tank 320 is therefore
defined
by the tank bottom portion 310, the tank entrance wall portion 304, the tank
circumferential wall portion 302, the prewash partition 340 and the center
wall
portion 308. The prewash dryer recovery tank 322 is separated from the wash
tank
324 by the prewash dryer partition 342. The prewash dryer recovery tank 322 is
therefore defined by the tank bottom portion 310, the prewash partition 340,
the
circumferential wall portion 302, the prewash dryer partition 342 and the
center wall
portion 308. The wash tank 324 is separated from the wash dryer recovery tank
326 by the wash partition 344. The wash tank 324 is therefore defined by the
prewash dryer partition 342, the circumferential wall portion 302, the wash
partition
344 and the center wall partition 308. The wash dryer recovery tanlc 326 is
separated from the rinse tanlc 328 by the wash dryer partition 346. Therefore,
the
wash dryer recovery tanlc 326 is defined by the tanlc bottom portion 310, the
wash
partition 344, the circumferential wall portion 302, the wash dryer partition
346 and
the center wall portion 308. The rinse tanlc 328 is separated from the rinse
dryer
recovery taW~ 330 by the rinse partition 348. Therefore, the rinse tank 328 is
defined by the tame bottom portion 310, the wash dryer partition 346, the
circumferential wall portion 302, the rinse partition 348 and the center wall
portion
308. The rinse dryer recovery tank 330 is separated from the final rinse tank
332 by the rinse dryer partition 350. Therefore, the rinse dryer recovery tank
330
may be defined by the tank bottom portion 310, the rinse partition 348, the
circumferential wall portion 302, the rinse dryer partition 350 and the center
wall
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partition 308. The final rinse tanlc 332 is separated from the final dryer
tank 334 by
the final rinse partition 360. Therefore the final rinse tanlc 332 is defined
by the
tank bottom portion 310, the rinse dryer partition 350, the circumferential
wall
portion 302, the final rinse partition 360 and the center wall portion 308.
The final
dryer tanlc 334 is defined by the tang bottom portion 310, the final rinse
partition
360, the circumferential wall portion 302, the tank exit wall portion 306 and
the
center wall portion 308.
Referring still to Fig. 2, the individual tanks 320, 322, 324, 326, 328,
330, 332 and 334 may be provided with various inlets and outlets. The inlets
are
provided for introducing solutions or compressed air into the tank area 300.
The
outlets may be provided for removing solutions from the tank area 300.
Examples
of inlets may include inlets 370, 372, 374, 376, 378, 380, 382, 384, 386, 388
and
390. Examples of outlets may include outlets 400, 402, 404 and 406. Since the
functions of the inlets and the outlets are substantially similar for the
individual
tanks, only one inlet and outlet will be described in detail.
In the exemplary embodiment, the wash tank 324 may be supplied
wash solution by three individual inlets 374, 376 and 378. The solution is
pumped
from the wash tanlc 324 from the outlet 402 by a pump (not shown). The pump
pressurizes the solution and delivers the solution to the three inlets 374,
376 and
378 by conventional tubing. In the exemplary embodiment, the pump may be of
the type manufactured by Kerr Machine Company of P.O. Box 91, Ada, Oklahoma
under the model name KZ-1000. As previously mentioned, this set of inlets and
outlet 374, 376, 378 and 402 are substantially similar to other sets of
fittings of the
can washer 100. Additionally, the wash tanlc 320 may be provided with an
overflow outlet 408. The overflow outlet 408 extends from the bottom portion
310 to a top surface (not shown) of the prewash solution. Removal of excess
prewash solution may occur through the overflow outlet 408 if the too much
prewash solution is located in the prewash tanlc 320.
In one embodiment of the present apparatus, the height of the internal
tanlcs such as tanks 320, 324 and 328 (Fig. 2) may have varying depths denoted
by
"D" in Fig. 8. The varying depths may be provided to make it possible to
constantly rejuvenate the various solutions. A predetermined flow rate, i.e. 2-
3
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gallons per minute, of clean potable water may be introduced to the rinse tank
328.
The rinse tank 328 may be deeper than the wash tank 324 (for example, "D" for
the
rinse tank 328 may be 2 inches greater than "D" for the wash tanlc 324);
therefore,
rinse solution flows from the rinse tanlc 328 into the wash tank 324 at the
same rate
at which the potable water is introduced to the rinse tank 328. The rinse
solution
that flows from the rinse tank 328 into the wash tank 324 is drawn from the
top
surface of the rinse solution. Most of the contaminants in the rinse solution
are
lighter than the rinse solution; therefore, the rinse solution that flows into
the wash
tank 324 moves contaminates from the rinse tank 328 to the wash tank 324. The
wash tank 324 may be deeper than the prewash tank 320 (for example, "D" for
the
wash tank 324 may be 2 inches greater than "D" for the prewash tank 320);
therefore, wash solution flows from the wash tank 324 into the prewash tank
320 at
the same rate at which the potable water is introduced to the rinse tai~lc
328. The
wash solution that flows from the wash tank 324 into the prewash tank 320 is
drawn from the top surface of the wash solution. Most of the contaminants in
the
wash solution are lighter than the wash solution; therefore, the wash solution
that
flows into the prewash tank 320 moves contaminates from the wash tank 324 to
the
prewash tank 320. Since wash solution is entering the prewash tank 320, the
volume of prewash solution would increase if not for the overflow outlet 408.
The
overflow outlet 408 allows prewash solution from the top surface of the
prewash
solution to be removed from the prewash tank 320. Most of the contaminants in
the
prewash solution are lighter than the prewash solution; therefore, the prewash
solution that flows into the overflow outlet 408 removes contaminates from the
prewash tank 320. The previously described method for introducing potable
water
into the rinse tank 328 and cascading the various solutions allows for
constant
rejuvenation of the solutions.
The tank assembly 300 may be provided with various manifolds for
directing solution or pressurized air. Three exemplary manifolds will be
described
herein. After providing the description of the three exemplary manifolds, an
exemplary orientation of the individual manifolds will be provided.
Referring to Fig. 3, a solution manifold 450 may be provided with a
conduit 452, an inlet fitting 454, a mounting portion 456 and a plurality of
outlets
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470, 472, 474, 476, 478, 480, 482, 484, 486 and 488. The solution manifold 450
may be further provided with a plurality of spray nozzles such as spray
nozzles 492,
494, 496, 498, 502, 504, 506 and 508. In the exemplary embodiment the spray
nozzles 492, 494, 496, 498, 502, 504, 506 and 508 may be substantially similar
to
those obtained from Spraying Systems Company of Wheaton, Illinois under the
model name LTNIJET part number TT-40015-SS. The solution manifold 450 may
be further provided with caps such as caps 490 and 500 for capping outlets
that are
not utilized. The conduit 452 is a substantially hollow member having a
substantially water-impermeable construction. In the exemplary embodiment,
stainless steel tube is provided having welded corners. The solution manifold
450
receives solution from a tank inlet, such as inlets 370, 374, 376, 378, 382
and 386,
and deliver the solution to the various outlets, such as outlets 470, 472,
474, 476,
478, 480, 482, 484, 486 and 488. The spray nozzles, such as 492, 494, 496,
498,
502, 504, 506 and 508 deliver solution shown as a shaded region in Fig. 3. The
particular configurations of the outlets provided with the solution manifold
450 may
be varied as required to obtain a particular spray pattern. The mounting
portion 456
is provided for attaching the solution manifold 450 to the tank assembly 300
by a
number of methods well known in the art. Methods of mounting may include, but
are not limited to, welds, rivets, threaded fasteners, adhesives, mechanical
interlocl~s, etc.
Referring to Fig. 4, a top air manifold 550 may be provided with a
conduit 552, a first fitting 554, a second fitting 556, a third fitting 558
and a
mounting portion 560. The conduit 552 is a substantially hollow member having
capped ends. In the exemplary embodiment, the conduit 552 is stainless steel
tubing having a bent portion 562. The top air manifold 550 may be further
provided with a first air nozzle 570 and a second air nozzle 572. The first
and
second air nozzles 570, 572 may be attached to the second and third fitting
556,
558, respectively. In the exemplary embodiment the first and second air
nozzles
570, 572 may be substantially similar to those obtained from Spraying Systems
Company of Wheaton, Illinois under the model name WINDJET part number
727-RY. The top air manifold 550 may receive compressed air from an inlet,
such
as inlets 372, 380, 384, 388 and 392, via a supply tube 574. The supply tube
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574 may deliver the compressed air to the first fitting 554, which in turn
delivers
compressed air to the first and second air nozzles 570, 572. The particular
configuration of the fittings provided with the top air manifold 550 may be
varied
as required for a particular spray pattern. The mounting portion 560 is
provided for
attaching the top air manifold 550 to the tanlc assembly 300 by a number of
methods well known in the art. Methods of mounting may include, but are not
limited to, welds, rivets, threaded fasteners, adhesives, mechanical
interlocks, etc.
Referring to Fig. 5, a circular air manifold 600 may be provided with
a conduit 602, plurality of fittings such as fitting 604, 606, 608, 610, 620,
622, 624,
626, 628 and 630, a mounting portion 640 and an opening 652. The conduit 602
is
a substantially hollow member having capped ends. In the exemplary embodiment,
the conduit 602 is stainless steel tubing having a plurality of bent portions
642, 644
and 646. The circular air manifold 600 may be further provided with a
plurality of
air nozzles such as air nozzle 648. In the exemplary embodiment the plurality
of
air nozzles such as air nozzle 648 may be substantially similar to those
obtained
from Spraying Systems Company of Wheaton, Illinois under the model name
WINDJET part number 727-RY. The air nozzle 648 may be attached to the second
fitting 620 or other fittings such as 604, 606, 608, 610, 620, 622, 624, 626,
628 and
610. The circular air manifold 600 may receive compressed air from an inlet,
such
as inlet 390, via a supply tube 650. The supply tube 650 delivers the
compressed
air to the fitting 390, which in turn delivers compressed air to the air
nozzle 648.
The particular configurations of the fittings provided with the circular air
manifold
600 may be varied as required for a particular air pattern. The mounting
portion
640 may be provided for attaching the circular air manifold 600 to the tank
assembly 300 by a number of methods well known in the art. Methods of mounting
may include, but are not limited to, welds, rivets, threaded fasteners,
adhesives,
mechanical interlocks, etc.
In an exemplary embodiment as shown in Fig. 2, the can washer 100
may be provided with a plurality of sprayer manifolds substantially similar to
the
sprayer manifold 450. A prewash sprayer 170, a first wash sprayer 174, a
second
wash sprayer 176, a third wash sprayer 178, a rinse sprayer 182 and a final
rinse
sprayer 186 may be provided with the can washer 100 and substantially similar
to
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the sprayer manifold 450 as previously described. The prewash sprayer 170 is
attached to the circumferential wall portion 302 in the general vicinity of
the
prewash tanlc 320. The first wash sprayer 174, the second wash sprayer 176 and
the
third wash sprayer 178 are attached to the circumferential wall portion 302 in
the
general vicinity of the wash tank 324. The rinse sprayer 182 is attached to
the
circumferential wall portion 302 and general vicinity of the rinse tank 328.
The
final rinse sprayer 186 is attached to the circumferential wall portion 302 in
the
general vicinity of the final rinse tank 332.
A prewash dryer 172, a washer dryer 180, a rinse dryer 184, a first
final dryer 188 and a third final dryer 192 may be provided with the can
washer
100 and substantially similar to the top air manifold 550. The prewash dryer
172 is
attached to the circumferential wall portion 302 in the general vicinity of
the
prewash dryer recovery tank 322. The wash dryer 180 is attached to the
circumferential wall portion 302 general vicinity of the wash dryer recovery
tank
326. The rinse dryer 184 is attached to the circumferential wall portion 302
in the
general vicinity of the rinse dryer recovery tank 330. The first final dryer
188 and
the third final dryer 192 are attached to the circumferential wall portion 302
in the
general vicinity of the final dryer tank 334.
A second final dryer 190 may be provided with the can washer 100
and substantially similar to the circular air manifold 600. The second final
dryer
190 is attached to the circumferential wall portion 302 in the general
vicinity of the
final dryer tanlc 334.
Referring to Fig. 6, the can washer 100 (Fig. 2) may be provided
with a retention turntable 700. The retention turntable 700 may be provided
with a
top portion 702, a bottom portion 704, a center portion 706, a perimeter 708
and a
plurality of can detents such as can detents 710, 712, 714 and 716.
Additionally the
retention turntable 700 may be provided with a plurality of drain holes such
as drain
holes 711, 713 and 715. Referring to Fig. 7, the retention turntable 700 may
be
provided with a top retention turntable 720.
The top retention turntable 720 may be provided with a top portion
722, a bottom portion 724, an inside portion 726, a perimeter 728 and a
plurality of
can detents such as can detent 730. The retention turntable 700 may be further
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provided with a top ring 740 and a bottom ring 750. The top ring 740 may be
provided with a top portion 742 and a bottom portion 744. The bottom ring 750
may be provided with a top portion 752 and a bottom portion 754. The retention
turntable 700 may be assembled with the top retention turntable 720, the top
ring
740 and the bottom ring 750. The top retention turntable 720 may be attached
with
a plurality of stanchions such as stanchion 764 by a plurality of bolts such
as bolts
760 and 762. The plurality of stanchions (such as stanchion 764) and plurality
of
bolts (such as 760 and 762) are provided circumferentially around the top
portion
702 of the retention turntable 700 located at a plurality of stanchion holes
such as
stanchion holes 770, 772 and 774 (Fig. 6). The top ring 740 is mounted to the
top
retention turntable 720 by a plurality of top mounting clamps such as top
mounting
clamp 780 and a plurality of mounting bolts such as mounting bolts 782 and
784.
The plurality of top mounting clamps such as top mounting clamp 780 are
provided
circumferentially around the top portion 722 of the top retention turntable
720
co-radial to the plurality of stanchion mounting bolts such as stanchion
mounting
bolts 760 and 762. The top mounting clamp 780 grips the top ring 740 and
secures
it by force applied by the mounting bolt 782. The bottom ring 750 is mounted
to
the retention turntable 700 by a plurality of bottom mounting clamps such as
bottom
mounting clamp 790 and a plurality of mounting bolts such as mounting bolts
792
and 794. The plurality of bottom mounting clamps such as bottom mounting clamp
790 are provided circwnferentially around the bottom portion 704 of the
retention
turntable 700 co-radial to the plurality of stanchion mounting bolts such as
stanchion mounting bolts 760 and 762. The bottom mounting clamp 790 grips the
bottom ring 750 and secures it by force applied by the mounting bolt 794.
Referring to Fig. 8, the retention turntable 700 may be provided with
a drive shaft 718. The drive shaft 718 may be mounted to the bottom portion
704
of the retention turntable 700. The drive shaft 718 and all components
operatively
attached thereto may be installed into the can washer 100 by a plurality of
bearings
such as the bearing 206. The drive shaft 718 may be rotated by the drive motor
(not shown) located in the frame 200. Therefore, the rotating drive shaft 718
rotates the retention turntable 700 and all components attached thereto within
the°
can washer 100.
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Referring to Fig. 7, the can washer 100 may be provided with a
guide rail 800. The guide rail 800 may be provided with a front surface 802
and a
mounting surface 804. The guide rail 800 may be further provided with a
plurality
of guide braclcets such as guide bracket 820. The plurality of guide brackets
such
as guide bracket 820 may be provided with a guide rail bolt 822, a vertical
portion
824, an interface portion 826 and a slot 828. The plurality of guide brackets
such
as guide braclcet 820 are attached to the tanlc assembly 300 at the partition
such as
prewash partition 340. The interface portion 726 is attached to the prewash
partition 340 by a pair of mounting bolts 830, 832. The guide rail 800 may be
secured in the can washer 100 by the guide rail bolt 822 that secures the
guide rail
to the vertical portion 824. The guide rail 800 may be provided in a
continuous
semi-circular location as best shown in Fig. 2. In an exemplary embodiment the
guide rail 800 is manufactured out of a wear-resistant material having a low
coefficient of friction such as ultra-lugh molecular weight polyethylene (UHF.
The guide rail 800 may be substantial similar to those manufactured by Slus
Industrial Innovations of 900C Tryens Road, Aston, Pennsylvania under the name
VALLT GUIDE model name VG-SSR. Additionally the plurality of guide brackets
such as guide bracket 820 may be positioned around the guide rail 800 for
support
at each of the partitions 304, 340, 342, 344, 346, 348, 350, 360 and 306.
Referring to Fig. 1, the can washer 100 may be provided with a
cover 900. The cover 900 may be provided with an outside perimeter 902, a top
portion 904, an entrance portion 906, an exit portion 908 and an inside
portion 910
(Fig. 8). The cover 900 may be further provided with a top prewash window 920,
a
top wash window 922, a top rinse window 924, a top final rinse window 926 and
a
top dryer window 928. The cover 900 may be further provided with a prewash
curtain 940, a prewash dryer curtain 942, a wash curtain 946, a wash dryer
curtain
948, a rinse curtain 950, a rinse dryer curtain 952 and a dryer curtain 954.
The
curtains 940, 942, 946, 948, 950, 952 and 954 may be provided on the inside
portion 910 of the cover 900. The individual curtains 940, 942, 946, 948, 950,
952
and 954, the entrance portion 906 and the exit portion 908 may be provided
with
openings such as opening 960 (Fig. 7) in the prewash curtain 940 (Fig. 7). The
cover 900 may be further provided with a perimeter prewash window 960, a
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perimeter wash window 962, a perimeter rinse window 964, a perimeter final
rinse
window 966 and a perimeter dryer window 968. In the exemplary embodiment, the
cover 900 is removably installed on the top portion of the tanlc assembly 300.
The exemplary embodiment as shown in Fig. 2 has a plurality of
individual stations that correspond to the individual tanks 320, 322, 324,
326, 328,
330, 332 and 334. The plurality of stations will hereinafter be referred to as
a
prewash station 110, a prewash dryer station 112, a wash station 114, a wash
dryer
station 116, a rinse station 118, a rinse dryer station 120, a final rinse
station 122
and a final dryer station 124. The prewash station 110 corresponds to the area
located above the prewash tanlc 320. The prewash dryer station 112 corresponds
to
the area located above the prewash dryer tank 322. The wash station 114
corresponds to the area located above the wash taut 324. The wash dryer
station
116 corresponds to the area located above the wash dryer tank 326. The rinse
station 118 corresponds to the area located above the rinse tank 328. The
rinse
dryer station 120 corresponds to the area located above the rinse dryer tank
330.
The final rinse station 122 corresponds to the area located above the final
rinse tank
332. The final dryer station 124 corresponds to the area located above the
final
dryer tank 334.
A plurality of cans, such as can 150, may be introduced into the can
washer 100 and travel in a semi-circular direction 160. During the course of
travel
each individual can, such as can 150 travels through the plurality of stations
such as
stations 114, 116, 118, 120, 122 and 124. In the exemplary embodiment there
are
six of these stations, however it should be understood that there may be fewer
or
more stations depending on the particular sequence, solutions used,
contaminates to
be removed, etc.
Referring to Fig. 7, the exemplary can 150 may be provided with a
circumferential wall 152, a bottom portion 154 and an open end 156. The can
circumferential wall 152 is provided with a circular geometry. The bottom
portion
154 may be located on a first end of the can circumferential wall 152 and the
open
end 156 may be oppositely disposed from the bottom portion 154. Therefore, the
can 150 has a 'cup' geometry having the open end 156 and the closed bottom
portion 154. In the exemplary embodiment, the can 150 is manufactured out of
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aluminum. Additionally, the exemplary aluminum can 150 may be altered in a
number of ways depending on the particular volumetric requirements, can
decoration, can composition, etc.
Having provided a detailed description of an exemplary embodiment
of the can washer 100, a description of the operation will now be provided
herein.
The can 150 may be introduced into the can washer 100 at the 132
by a conveyer system (not shown). Conveyer systems of this type are readily
available by a variety of manufacturers. The can 150 may be introduced with an
orientation such that the circumferential wall 152 is positioned vertical
(thereby
parallel to the direction of gravity). The can 150 may also be positioned such
that
the can bottom portion 154 is located above (i.e. away from the ground) the
open
end 156 as shown in Fig. 7 with this orientation, the can 150 does not collect
solution against the bottom portion 154. It should be appreciated that this
particular
orientation may be altered depending on the particular geometry of the article
to be
washed.
The conveyer system (not shown) introduces the can 150 into one of
the plurality of retention turntable can detents, such as retention turntable
can detent
716. Referring to Fig. 7, the can bottom portion 154 may be in contact with
the
bottom portion 744 of the top ring 740. The can open end 156 may be in contact
with the top portion 752 of the bottom ring 750. The can circumferential wall
152
may be in contact with the retention turntable can detent 716. The retention
turntable 700 is rotating in the rotary direction 160. Therefore, the can 150
as
captured by the can detent 716 on the retention turntable 700 rotates in the
rotary
direction 160. Shortly after rotating in the rotary direction 160, the can 150
may
contact the guide rail 800. The can 150 may therefore be secured at a portion
of
the can circumferential wall 152 by the top retention turntable can detent 730
and
the retention turntable can detent 716; an oppositely disposed portion of the
can
circumferential wall 152 may be secured by the guide rail 800. The
interactions
between the can detent 730, the can detent 716, the top ring 740, the bottom
ring
750 acid the guide rail 800 restrain the can 150 and resist forces applied
thereto.
Forces such as forces of sprayed solutions, air baffles curtains and
centrifugal forces
may be applied to the can as part of the cleaning process.
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While rotating in the rotary direction 160, the can 150 passes the
cover entrance portion 906 through an opening (not shown but substantially
similar
in geometry to the cover entrance portion 906 (Fig. 7)) and into the cover
900.
While traveling through the cover 900, the guide rail 800 continues to contact
the
can circumferential wall 152 as previously described.
As can 150 travels in the rotary direction 160, it may pass through
various stages. After entering the cover 900 the can 150 is located in the
prewash
station 110. While traveling through the prewash station 110, the can is
sprayed by
a prewash solution of sulfuric acid, hydrofluoric acid and surfactants. As
previously
mentioned, the prewash solution may be previously used wash solution. Addi-
tionally, the prewash solution may be heated to an elevated temperature such
as 120
degrees Fahrenheit. The prewash solution is sprayed from the prewash sprayer
170.
The sprayed prewash solution is obtained from the inlet 370 and plumbed to the
plurality of nozzles as substantially shown in Fig. 3. After the sprayed
prewash
solution contacts the can 150, the prewash solution is collected in the
prewash tank
320. The collected prewash solution is evacuated from the prewash tank 320
through the outlet 400. The evacuated prewash solution may travel from the
outlet
400 into a pump (not shown) and reintroduced to the inlet 370. The
recirculation of
the prewash solution conserves the solution and minimizes the loss should
total
discharge be required. After traveling through the prewash station 110, the
can 150
passes the prewash curtain 940 and the prewash partition 340 and into the
prewash
dryer station 112.
While traveling through the prewash dryer station 112, the can 150 is
subj ected to air discarded by the prewash dryer 172. The air discharged by
the
prewash dryer 172 blows any remaining prewash solution off the can 150 and
into
the prewash dryer recovery tank 322. The air being discharged by the prewash
dryer 172 may be obtained from a conventional air compressor and introduced to
the prewash dryer 172 through the inlet 372.
As can 150 continues to travel in the rotary direction 160, it may
pass from the prewash dryer station 112 into the wash station 114 past the
prewash
dryer curtain 942 and the prewash dryer partition 342. While traveling through
the
wash station 114, the can 150 may be sprayed by a wash solution of sulfuric
acid,
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hydrofluoric acid and surfactants. A controller may be provided that senses if
component ratios are incorrect and adjusts component ratios as needed. Addi-
tionally, the prewash solution may be heated to an elevated temperature such
as 120
degrees Fahrenheit. The wash solution may be sprayed from the first wash
sprayer
174. The wash solution sprayed from the first wash sprayer 174 may be obtained
from the inlet 374 and plumbed to the plurality of nozzles as substantially
shown in
Fig. 3. The wash solution may also be~ sprayed from the second wash sprayer
176.
The wash solution sprayed from the second wash sprayer 176 may be obtained
from
the inlet 376 and plumbed to the plurality of nozzles as substantially shown
in Fig.
3. The wash solution may also be sprayed from the third wash sprayer 178. The
wash solution sprayed from the third wash sprayer 178 may be obtained from the
inlet 378 and plumbed to the plurality of nozzles as substantially shown in
Fig. 3.
After the sprayed wash solution contacts the can 150, the wash solution may be
collected in the wash tank 324. The collected wash solution may be evacuated
from
the wash tanl~ 324 through the outlet 402. The evacuated wash solution may
travel
from the outlet 402 into a pump (not shown) and reintroduced to the inlets
374, 376
and 378. The recirculation of the wash solution conserves the solution and
minimizes the loss should total discharge be required. After traveling through
the
wash station 114, the can 150 may pass the wash curtain 946 and the wash
partition
344 and into the wash dryer station 116.
While traveling through the wash dryer station 116, the can 150 may
be subjected to air discarded by the wash dryer 180. The air discharged by the
wash dryer 180 may blow any remaining wash solution off of the can 150 and
into
the wash dryer recover tank 326. The air being sprayed by the wash dryer 180
may
be obtained from a conventional air compressor and introduce to the wash dryer
180
through the inlet 380.
As can 150 continues to travel in the rotary direction 160, it may
pass from the wash dryer station 116 into the rinse station 118 past the wash
dryer
curtain 948 and the wash dryer partition 346. While traveling through the
rinse
station 118, the can 150 may be sprayed by a rinse solution of potable water.
The
rinse solution may be sprayed from the rinse sprayer 182. The rinse solution
sprayed from the rinse sprayer 182 may be obtained from the inlet 382 and
plumbed
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to the plurality of nozzles as substantially shown in Fig. 3. After the
sprayed rinse
solution contacts the can 150, the rinse solution may be collected in the
rinse tank
328. The collected rinse solution may be evacuated from the rinse tank 328
through
the outlet 404. The evacuated rinse solution may travel from the outlet 404
into a
pump (not shown) and reintroduced to the inlet 382. The recirculation of the
rinse
solution conserves the solution and minimizes the loss should total discharge
be
required. After traveling through the rinse station 118, the can 150 may pass
the
rinse curtain 950 and the rinse partition 348 and into the rinse dryer station
120.
While traveling through the rinse dryer station 120, the can 150 may
be subjected to air discharged by the rinse dryer 184. The air discharged by
the
rinse dryer 184 may blow any remaining rinse solution off the can 150 and into
the
rinse dryer recovery tank 330. The air being discharged by the rinse dryer 184
may
be obtained from a conventional air compressor and introduced to the rinse
dryer
184 through the inlet 384.
As can 150 continues to travel in the rotaxy direction 160, it may
pass from the rinse dryer station 120 into the final rinse station 122 past
the rinse
dryer curtain 952 and the rinse dryer partition 350. While traveling through
the
final rinse station 122, the can may be sprayed by a final rinse solution of
deionized
water. The final rinse solution may be sprayed from the final rinse sprayer
186.
The final rinse solution sprayed from the 186 may be obtained from the final
rinse
sprayer 386 and plumbed to the plurality of nozzles as substantially shown in
Fig. 3.
After the sprayed final rinse solution contacts the can 150, the final rinse
solution
may be collected in the final rinse tank 332. The collected final rinse
solution may
be evacuated from the final rinse tank 332 through the outlet 406. The
evacuated
final rinse solution may travel from the outlet 406 into a pump (not shown)
and
reintroduced to the inlet 386. The recirculation of the final rinse solution
conserves the solution and minimizes the loss should total discharge be
required.
After traveling through the final rinse station 122, the can 150 passes the
dryer
curtain 954 and the final rinse partition 360 and into the final dryer station
124.
While traveling through the final dryer station 124, the can 150 may
be subjected to air discarded by the first final dryer 188, the second final
dryer 190
and the third final dryer 192. The air discharge from the first final dryer
188, the
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second final dryer 190 and the third final dryer 192 may blow any remaining
final
rinse solution off of the can 150 and into the final dryer tanlc 334. The air
being
sprayed by the first final dryer 188, the second final dryer 190 and the third
final
dryer 192 may be obtained from a conventional air compressor and introduce to
the
first final dryer 188 through the inlet 388, inlet 390 and the inlet 392,
respectively.
Upon traveling through the final dryer station 124, the can 150 may
pass the exit portion 908 and enter the exit portion 132. At the exit portion
132 the
can 150 may come into contact with a conventional conveyer system. The exiting
can 150 may be substantially free of contaminates and ready to be introduced
to
additional manufacturing stations such as surface activation stations,
printing
stations, filling stations, etc.
In an alternative embodiment, holes may be provided to create
varying depths of the internal tanks such as tanks 320, 324 and 328 (Fig. 2)
denoted
by "D" in Fig. 8. In this embodiment, holes may be provided in the internal
tank
partitions such as partitions 340, 342, 344 and 346 (Fig. 2) to create the
varying
depths. The holes allow the various solutions to cascade from one tank to
another
such as from the rinse tanlc 328 into the wash tank 324.
The present apparatus provides a modular approach to cleaning cans
during the manufacturing process. Due to the small footprint and throughput
capability of the apparatus, the apparatus may be installed near the bodymaker
machine. With such installation, a plurality of smaller machines may take the
place
of a single large wash system as used in the prior art. Using a plurality of
smaller
machines in this manner allows portions of the production line to be shut down
without causing the entire line to be shut down. When shutting down these
individual stations, only the cans in the particular can washer are subject to
over-processing. It can be appreciated by those in the art that fewer cans may
require discarding due to over-processing versus the prior art washing system
having
a large number of cans therein.
An additional consideration of the individual stations is the size of
the reservoir tanks. Since the present apparatus has smaller tanks, the effect
of
contamination may be minimized. In the event that rejuvenation of the
solutions is
required, only the particular individual solution in one tank needs to be
rejuvenated.
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Additionally, in the event that the solution has become damaged beyond the
point of
rejuvenation, it may be discarded. The volume of discharged solution of the
present
apparatus is substantially smaller than the prior art devices.
Additionally, the present apparatus confines each individual can with
minimal contact area therefore maximizing accessibility to solutions. As such,
the
cans are subjected directly to sprayed solutions rather than through conveyer
belts or
between 'tubes' created by other adjacent cans.
Since the cans in the high-speed washer 100 are confined, higher
pressure sprayers may be used. The higher pressure sprayers provide additional
mechanical cleaning action to remove contaminates from the cans. The higher
pressure provides a mechanical cleaning action as well as the chemical
cleaning
action of the solution. The mechanical cleaning action is due to the higher
velocity at which the solution is traveling as it contacts the cans. The
present
apparatus may be capable of spraying solutions in the range of 300-500 p.s.i.
whereas the conventional systems provide pressures in the 50-60 p.s.i. range.
It is
noted that some objects are relatively light, such as aluminum cans that
typically
weigh 11 grams for a 12-ounce beverage can. The present apparatus confines
light
objects, i.e. aluminum cans, such that the pressure does not dislodge the
object,
whereas the prior art typically accommodates lower pressures.
Although in the exemplary embodiment the can 150 was used to
describe the cleaning process, it is to be understood that the machine may be
adapted to clean a variety of articles. As such, the present apparatus may be
used to
clean various articles other than cans.
